Jack, I experimented 30 years ago with the BPD and loads for my NID 10 3.5". In altering the slit of the BPD, I tried 2 and 3 petals rather than 4 or with 4 shallow petals in efforts to tighten patterns after reaching max denisity with buffer, etc. The loads would sometimes suffer "wad flip" wherein the wad would flip over in flight with a partial load of shot inside the wad and imbed itself in the patterning board leading with the gas seal. I found it best to slit the wad as described by BP. The BP booklets had the best published loads back then for the BPD.
If you can, post photos of your brute, we'd love to see it. Gil